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Corresponding Author

Ibrahim, A.

Subject Area

Mechanical Power Engineering

Article Type

Original Study

Abstract

The paper describes theoretical and experimental analysis of dynamics of system: grinding wheel- workpiece external cylindrical plunge grinding process to study the effect of workpiece previous profile on the ground workpiece roundness. The study has been carried out theoretical model taking contact stiffness of system (workpiece and machine), grinding wheel and workpiece wear into consideration. The results showed that mode shape vibration errors are strongly depends on amplitude of initial workpiece profiles. The mode shape vibration errors increases with the increase of initial workpiece profiles amplitudes and workpiece length. Experiments had been carried out on identical specimens. These specimens were turned first with different cutting conditions to obtain different profiles. Then a cylindrical plunge grinding operation with the same cutting conditions was applied for the resulted specimens. The vibration signals existing during grinding were recorded. The resulted roundness error before and after grinding were compared for each specimens. The results showed the root mean square (RMS) of vibration level, roundness error and undulation number of the ground workpiece are dependent on the initial workpiece profile. The comparison between theoretical and experimental results showed as good agreements. To compensate roundness error within an acceptable range, fuzzy knowledge base controller (FKBC) was proposed. The proposed fuzzy controller predicts the work piece shape error more accurately, and reduces it by about 20%

Keywords

Plunge grinding; Vibration; Roundness; initial profile; undulation; flexibility; Fuzzy controller

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